Hoyer HMA4 User manual

Electric Motors
Motor Manual

2
Motor
Manual
Contents
1 Notice.......................................3
1.1 General information ..........................3
1.2 Safety instructions............................3
1.2.1 Operation ...................................3
1.2.2 Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.3 Transport....................................3
2 Ex nA/ec and tc motors .......................4
2.1 Cable glands and connection...................4
2.2 Maintenance and spare parts ..................4
2.3 Frequency converter operation .................4
3 Receipt, transport and storage..................5
3.1 Receipt and transport .........................5
3.2 Storage......................................5
4 Installation and commissioning ................7
4.1 General .....................................7
4.2 Support and alignment........................7
4.3 Measure the insulation resistance ..............7
5 Electrical connection and cabling ...............9
5.1 Direction of rotation ..........................9
5.2 Terminal box and terminal board ...............9
5.3 Connection diagram .........................10
6 Thermal protection ..........................11
6.1 Thermal protection with thermistors (PTC)......11
6.2 Thermal protection with bimetal switches ......11
6.3 Temperature monitoring with Pt100 sensors ....11
6.4 Heater strip.................................11
7 Motor data and parts ........................12
7.1 Exploded view of motor and cross-section view..12
7.2 Bearing types for motor sizes. . . . . . . . . . . . . . . . . . 13
7.3 Permissible axial and radial bearing loads.......17
8 Frequency converter operation ................30
8.1 Operating speed .............................30
8.2 Winding insulation ..........................30
8.3 Bearing deterioration in relation to VFD.........30
8.4 Additional solutions for limitation
of bearing currents ..........................31
8.5 Hoyer VFD application suggestions.............31
9 Operation ..................................32
9.1 Considerations ..............................32
9.2 Checklist ...................................32
9.3 Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.4 Motor operation with a VFD ...................33
9.5 Operating speed .............................33
10 Maintenance................................34
10.1 General ....................................34
10.2 Bearings and re-greasing .....................34
11 Disposal and environmental protection ........37
11.1 Product disposal information. . . . . . . . . . . . . . . . . . 37
11.2 RoHS and REACH ............................37
11.3 Electric motors ..............................37
11.4 Packaging material ..........................37

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Motor
Manual
1 Notice
This manual must be followed to ensure proper and safe
installation, operation and maintenance of the motor. Prod-
ucts must be handled by qualified personnel, and health
and safety requirements and national legislation must be
observed. Ignoring these instructions will invalidate all ap-
plicable warranties of Hoyer Motors.
1.1 General information
This manual concerns the following types of standard low
voltage induction motors from Hoyer Motors: HMA4, HMC4,
HMA3, HMC3, HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2,
YDT. Explosion-proof low voltage motors are not covered by
this manual.
All motors are manufactured in accordance with IEC/
EN 60034-1 and IEC/EN 60072 unless otherwise specified.
Motors are rated as standard for the ambient temperature
range of -20°C to +40°C and site altitudes up to 1000 m above
sea level. Low voltage motors are components for installa-
tion in machinery. The motors are CE marked according to
the Low Voltage Directive 2014/35/EU.
Motors not fulfilling the IE3 efficiency level must, before the
1st of July 2021, be equipped with variable frequency drives
(VFD) when used in the EU. Information about the required
use of a VFD must be shown on the nameplate or an ad-
ditional label or plate, and in the technical documentation
of the motor.
1.2 Safety instructions
Personnel who commission, transport, maintain or install
motors should have obtained qualified training and safety
knowledge. Safety equipment is necessary to prevent ac-
cidents. Local regulations and requirements must also be
observed. Failure in operation can cause injury to personnel
and damage to the motor.
The specified data and recommendations must be observed to
avoid hazardous situations and the risk of injury or damage.
Custom designs and other non-standard motors can vary in
technical details. If in doubt contact Hoyer Motors, stating
the type designation and serial number of the motor.
1.2.1 Operation
For safe operation it must be ensured that no external parts
interfere with the rotating shaft.
The shaft key must be securely fastened in the keyway be-
fore the motor is started. If the motor is run for no-load
testing, the key must be fixed in the keyway or removed.
The motor must be handled and operated properly to avoid
accidents during operation. If the motor is not running
properly, switch off the power supply. The power supply
must be switched off when troubleshooting.
Maintenance is required and must be done on a regular ba-
sis to prevent failures.
1.2.2 Lifting
For safety reasons all Hoyer motors with frame size 100 or
larger are equipped with eyebolts for lifting. Before lifting
the motor, ensure that the eyebolts are undamaged and
screwed tight. When lifting the motor, make sure that the
motor is not attached to any equipment or mounted by the
feet, shaft or flange. Only use the main eyebolts on the mo-
tor frame to lift the motor. Do not use damaged eyebolts.
If crane slings are used, prevent them from slipping and
maintain full control when lifting the motor.
1.2.3 Transport
The motor must be fixed on a pallet (by ropes, cables, bolts,
etc.) during transport. This means it must be secured so
it cannot move or be damaged during transport. Broken
equipment and unstable machines can cause serious inju-
ries.

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Motor
Manual
2 Ex nA/ec and tc motors
Below information is a special note for Ex nA/ec and tc mo-
tors.
Designation of motors is according to EN/IEC standard: II 3D
Ex tc IIIB T120°C Dc and II 3G Ex nA/ec IIC T3 Gc. The motors
must only be connected to certified Ex relays. The hazard-
ous 3-phase asynchronous motors are in accordance with
EU directive 2014/34/EU and international standards EN/IEC
60079-0, EN/ IEC 60079-07, EN/IEC 60079-15 and IEC 60079-
31. Only one electrical installation may be installed in one
specified area(zone). For Ex ec parameter Time E must be
taken into account.
2.1 Cable glands and connection
Only Ex certified cable glands may be used. Unused glands
must be closed by Ex certified blind caps.
When connecting, make sure that a permanently safe elec-
trical connection is maintained, both for the main supply
and earth connection. Installations must be in accordance
with actual standards for installation in hazardous area.
2.2 Maintenance and spare parts
The user is responsible for changing parts in accordance
with life time of arts, in particular: bearings, grease and lu-
brication of shaft sealings. Installation, maintenance, repair
and replacement of parts in this type of motors must only
be carried out by qualified specialists according to EU di-
rective 99/92, EN/IEC 60079-14, EN/IEC 60079-17 and EN/IEC
60079-19.
It is recommended that the IEC standard is followed ac-
cording to the temperature and dust on the motor surface.
Surface dust must not cause increase of motor tempera-
ture. Regularly cleaning is recommended. The radial shaft
sealing ring is part of the EX certification. It is important
that the sealing rings are intact. The shaft sealing must be
checked regularly, and if it is dry it must be lubricated. It
is recommended that the motors are re-lubricated regular-
ly. When replacing seal rings, use original ones. Replacing
bearings also means replacing the seals. All machines must
be inspected regularly for mechanical damage.
2.3 Frequency converter operation
For converter use, PTC has to be connected and only for
quadratic torque application, in frequency range 20-60Hz,
switching frequency ≥2000 Hz and Inverter output du/dt ≤
1350V/0,8µs by reinforced winding du/dt ≤1560V/0,5µs

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Motor
Manual
3 Receipt, transport and storage
3.1 Receipt and transport
Upon receipt and for transport:
• Use transport locks for all transport operations.
• Avoid moisture and shocks during transport.
• Check the motor for external damage.
• If damage is found, inform the sales representative of
Hoyer Motors.
• Check all nameplate data and compare it with the re-
quirements for the motor.
• Remove transport locks if present.
• Turn the shaft by hand to check for free rotation.
3.2 Storage
• Ensure the use of correct lifting lugs. Lifting lugs are
dimensioned for the weight of the motor.
• Do not apply extra weight.
• If necessary, use suitable special equipment such as
lifting gear and ropes.
• Store in a dry, dust-free and vibration-free location.
• Carefully consider long-term storage procedures.
Short-term storage (less than 2 months)
The motor should be stored in a place with a controllable
environment. A good warehouse or storage location has:
• Measure the insulation resistance and temperature
of the windings to check whether the motor has been
stored improperly, even for a short time.
• A stable temperature, preferably in the range from 10°C
(50°F) to 50°C (120°F). If the anti-condensation heaters
are energised and the surrounding air is above 50°C
(120°F), ensure that the motor is not overheated.
• Low air humidity, preferably below 75%. The motor
temperature must be kept above the dew point shown
in the figure to prevent water vapour from condensing
inside the motor. If the motor is equipped with anti-
condensation heaters, they should be energised. Proper
operation of the anti-condensation heaters must be
checked periodically. If the motor is not equipped with
anti-condensation heaters, other methods of heating
the motor must be used to prevent water vapour from
condensing in the motor.
• A stable support free from excessive vibration and
shocks. If vibration levels are expected to be too large,
the motor should be isolated by placing suitable rubber
blocks under the motor feet.
• Air that is ventilated, clean and free from dust and cor-
rosive gases.
• Protection against harmful insects, vermin and chemi-
cals.
Long-term storage (more than 2 months)
In addition to the measures described for short-term stor-
age, the following actions are necessary:
• Measure the insulation resistance and temperature
of the windings to check whether the motor has been
stored improperly, even for a short time.
• Check the condition of the paintwork every three
months. If corrosion is seen, remove it and apply a new
coat of paint.
• Check the condition of the anti-corrosion coating on
bare metal surfaces every three months. If corrosion is
seen, remove it gently with emery cloth and apply an
anti-corrosion coating.
• Provide small ventilation openings if the motor is
stored in a wooden crate. Prevent water, dust and in-
sects from entering the crate.

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Motor
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Outdoor storage
If the motor must be stored outdoors, never leave the motor
as is in the standard transport packaging. Instead the motor
must be:
• Taken out of its plastic wrap.
• Covered to completely prevent rain from entering the
motor. The cover should allow ventilation of the motor.
• Placed on at least 100 mm (4”) high rigid supports, to
ensure that no moisture can enter the motor from be-
low.
• Protected against harmful insects and vermin.
• Packed in special outdoor packaging.
Drain plugs
The motor is equipped with drain plugs to let condensa-
tion water drain out. The drain plugs should be open when
stored.
Horizontal mounting: For horizontally mounted motors,
drain plugs are fitted at each end of the motor.
Vertical mounting: For vertically mounted motors, a mini-
mum of two drain plugs are fitted on the lower end shield.

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Motor
Manual
4 Installation and commissioning
4.1 General
To ensure correct protection and connection of the motor,
check the nameplate data before installation and commis-
sioning. Before working on the motor, disconnect and lock
out the power supply. Before starting the motor, remove the
transportation bracket and clean the shaft, feet and flange
to remove the protective coating. It is recommended to
grease the bearing during initial commissioning according
to Table 15, Re-greasing interval and amount.
When performing installation and commissioning, make
sure that the motor is earthed. When making insulation re-
sistance measurements for commissioning, short the wind-
ing terminals before disconnecting the test leads to avoid
the risk of electric shock. If the motor windings have been
in contact with sea water, they must be inspected (contact
Hoyer Motors).
Avoid resonances with a rotational frequency at twice the
mains frequency due to assembly. Turn the rotor and listen
for abnormal rubbing noises. Check the direction of rota-
tion with the motor uncoupled. When mounting or remov-
ing couplings or other drive elements, cover them with a
touch guard.
For a test run with the motor uncoupled, secure or remove
the key(s) on the rotor shaft. Avoid excessive radial and
axial bearing loads, except with roller bearings or angular
contact bearings (see section 6.2).
Rotor balance:
• Half key as standard: Couplings must be half key bal-
anced. If part of the shaft key is visible, be sure to per-
form mechanical balancing.
• Full key (non-standard): Couplings must be balanced
without a key.
Ensure the required ventilation and clearance from other
objects; see section 8.4. Do not obstruct ventilation open-
ings, and ensure that exhaust air from other equipment is
not drawn into the ventilation openings. Otherwise the mo-
tor may overheat.
4.2 Support and alignment
The end-user is fully responsible for construction of the
support. The contact surface for the motor feet or flange
must be free of paint, dirt and other objects. Otherwise the
motor height may be incorrect or the motor may be mis-
aligned.
Mount the motor on a sturdy, clean and flat support. It must
be sufficiently rigid to withstand short circuit forces. It is
important to ensure that the mounting conditions do not
cause resonance at the rotational frequency or twice the
supply frequency.
Always use suitable tools to mount or remove drive com-
ponents. Do not hit the drive components with a hammer,
as this can damage the bearings or degrade the balancing.
The rotors are balancing with a half key for G2.5 according
to ISO 21940-11. Make sure that the drive components are
the same. Correct alignment is essential to avoid bearing
failure, shaft failure and vibration failure. Use only suita-
ble alignment methods. Re-check the alignment after final
tightening of the bolts or studs. Check that drain holes and
plugs face downwards and are fully functional and unob-
structed. With a motor that is installed outdoors or that
does not run continuously, open the drain hole so the motor
housing is ventilated.This keeps the motor dry if a heater is
not fitted in the motor or not energised.
Check these measurements before adjusting the alignment
- not all variants are covered:
• Vertical positioning: To avoid motor tipping and bend-
ing, use shims to stabilise the motor.
• Horizontal positioning: Fix the motor axial position and
make sure the axial gap is uniform.
• Stable support: Vibration free, accurate machine align-
ment and balanced drive.
• Foot/Foot-flange mounting: Mount the motor with
the right bolts and tightening torques. Make sure the
motor feet and/or flange bolts are in full contact with
the mounting surface.
4.3 Measure the insulation resistance
Before commissioning, check the datasheet and measure
the insulation resistance without any supply wires con-
nected, as they can distort the measurement. If the meas-

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Motor
Manual
ured insulation resistance is less than 10 MΩat 25°C, the
winding must be oven dried. The nominal value is typically
100 MΩ. If the measured value is less than 2 MΩ, the insu-
lation resistance is not acceptable. When oven drying the
windings, set the oven temperature to approximately 85°C
for 10 to 18 hours, followed by 100°C for 7 to 9 hours. The
nominal insulation resistance drops by 50% for every 20°C
rise in motor temperature. Measuring equipment must al-
ways be calibrated at least every year. Note that drain plugs
or valves must be open during heating. After heating, make
sure the plugs are fitted again.

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Motor
Manual
5 Electrical connection and cabling
The motors are designed to operate with supply variations
conforming to IEC 60034-1, Zone A: ±5% voltage and ±2%
frequency. The motors will operate with greater variations
according to Zone B of IEC 60034-1 section 7.3, but with larg-
er variation in performance.
Three-phase motors manufactured by Hoyer Motors are
designed according to IEC 60038 and IEC 60034-1 and can
operate with the rated power and torque load within the
mains voltage and frequency variations of zone A and, for a
short time, of zone B.
Single-phase Hoyer motors can operate under these condi-
tions with mains voltage and frequency variations of ±5%
and ±1%, respectively. If the voltage variation is greater, sin-
gle-phase motors can only be operated with the torque load
adjusted in proportion to the voltage dip.
Earthing must be carried out according to local regulations
before the motor is connected to the supply voltage.
5.1 Direction of rotation
Motors are supplied as standard with clockwise rotation as
seen from the drive end. The phase sequence is L1, L2, L3
as connected to the terminals shown in Figure 1. To change
the direction of rotation, change the phase sequence by (for
example) swapping L1 and L2. If the motor is unidirectional,
make sure the shaft rotates in the same direction as the
marked arrow.
5.2 Terminal box and terminal board
The terminal box contains the earthing terminal, terminal
board and terminals for heating elements and temperature
sensors (PTC and Pt100). Other auxiliary devices may also
be located in the terminal box. Hoyer motors are equipped
with three PTC sensors as standard. Heating elements are
common in Hoyer marine motors with frame size 160 or
larger.
Before working on the motor or attached machinery:
• Ensure that all supply voltages are switched off and
protected against reactivation.
• Switch off auxiliary power circuits for accessories such
as anti-condensation heaters.
• Check the supply voltage and frequency by comparing
them with the rated data on the nameplate and the
data sheet.
• Ensure that the terminal box is clean and dry.
• Close unused cable glands with blind caps.
• Check the terminal box cover gasket before refitting.
Always use suitable cable lugs for connection of all main
supply cables and cables for auxiliary devices, and ensure
that cables are corrected to the correct terminals.
Unless otherwise stated, motors are only intended for fixed
installation. Cable glands/blind caps for entry points are met-
ric. If cable glands or blind caps are replaced, the replace-
ments must be at least the same IP class as the existing items.
Connection diagrams for the main supply and accessories
such as PTC sensors or heaters are located inside the termi-
nal box or cast in the terminal box cover.
All crimped connections should be made according to
IEC 60352-2.
Tightening torques for terminal board studs:
Thread M4 M5 M6 M8 M10 M12 M14 M16 M20
T (Nm) 1.8 2.5 3.5 7.0 12 18 35 55 80
Table 1 Terminal board tightening torques
Tightening torques for terminal box cover:
Thread HMA -
M4
HMC -
M4
HMA -
M5
HMC -
M5
M6 M8 M10 M12
T (Nm) 1.1-1.3 2-4 1.1-1.3 2-4 6-8 15.5-17.5 31-35 56-60
Table 2 Terminal box cover tightening torques
To comply with EMC requirements and provide proper
earthing, cables must be shielded and EMC cable glands are
recommended. All incoming parts must have the same po-
tential as the motor.
Cable glands and seals in cable entries must be suitable
for the type and diameter of the cable concerned (clamp-
ing range). It is recommended that cables are mechanically
protected and clamped close to the terminal box to fulfil the
requirements of IEC 60079 and local requirements.

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Motor
Manual
5.3 Connection diagram
As standard all three-phase motors are suitable for 400 V
connection, unless otherwise stated.
• Motors with nameplate data D/Y 230/400V are connect-
ed as star (Y).
• Motors with nameplate data D/Y 400/690V are connect-
ed as delta (D).
The connection diagram is labelled inside the terminal box.
Generally, power to motors must be supplied and protected
through protective devices such as RCDs, fuses, MCBs, MC-
CBs, etc. The connection diagram for Y/D is shown in Fig-
ure 1.
Figure 1 Connection types Y/D
Star-delta starting
Hoyer standard motors are suitable for star-delta starting.
The starting current and torque in Y mode are approxi-
mately one-third of the starting current and torque in D
mode. Make sure there is enough starting torque to acceler-
ate the total load with star connection.